CN107507673B - Composite cable for robot and preparation method thereof - Google Patents
Composite cable for robot and preparation method thereof Download PDFInfo
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- CN107507673B CN107507673B CN201710766881.1A CN201710766881A CN107507673B CN 107507673 B CN107507673 B CN 107507673B CN 201710766881 A CN201710766881 A CN 201710766881A CN 107507673 B CN107507673 B CN 107507673B
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- 239000002131 composite material Substances 0.000 title claims abstract description 78
- 238000002360 preparation method Methods 0.000 title abstract description 12
- 230000005540 biological transmission Effects 0.000 claims abstract description 94
- 239000000945 filler Substances 0.000 claims abstract description 68
- 230000008054 signal transmission Effects 0.000 claims abstract description 59
- 239000000463 material Substances 0.000 claims description 135
- 238000013461 design Methods 0.000 claims description 116
- 239000004760 aramid Substances 0.000 claims description 109
- 229920003235 aromatic polyamide Polymers 0.000 claims description 101
- 239000004020 conductor Substances 0.000 claims description 87
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 85
- 229920000742 Cotton Polymers 0.000 claims description 74
- 229920000728 polyester Polymers 0.000 claims description 74
- 239000000203 mixture Substances 0.000 claims description 66
- 229910052802 copper Inorganic materials 0.000 claims description 61
- 239000010949 copper Substances 0.000 claims description 61
- 239000004033 plastic Substances 0.000 claims description 36
- 238000001125 extrusion Methods 0.000 claims description 35
- 239000004745 nonwoven fabric Substances 0.000 claims description 32
- 238000000034 method Methods 0.000 claims description 29
- 238000002156 mixing Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 238000005452 bending Methods 0.000 abstract description 10
- 229920006231 aramid fiber Polymers 0.000 description 8
- 238000012545 processing Methods 0.000 description 4
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 241000282414 Homo sapiens Species 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/06—Gas-pressure cables; Oil-pressure cables; Cables for use in conduits under fluid pressure
- H01B9/0605—Gas-pressure cables with enclosed conduits
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/02—Cables with twisted pairs or quads
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/02—Stranding-up
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/02—Stranding-up
- H01B13/04—Mutually positioning pairs or quads to reduce cross-talk
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/08—Several wires or the like stranded in the form of a rope
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1895—Internal space filling-up means
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
- D07B1/147—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising electric conductors or elements for information transfer
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a composite cable for a robot and a preparation method thereof. The composite cable is provided with a total cable core, an outer wrapping layer and an outer sheath layer, wherein the outer wrapping layer is wrapped outside the total cable core; the main cable core is mainly formed by twisting at least one pneumatic transmission tube, at least one signal cable and at least one power cable, an outer filler is filled in a twisting gap of the main cable core, the signal cable and the power cable are respectively formed by twisting a plurality of insulating wire cores, and twisting directions of the insulating wire cores of the signal cable and the power cable are respectively the same as the twisting direction of the main cable core. The invention effectively, stably and compactly integrates the functions of pneumatic transmission, electric power transmission and signal transmission, and the cable structure can lead the product to have excellent flexibility and tensile strength, good bending resistance and torsion resistance and long service life, thereby being particularly suitable for robots with repeated bending and torsion actions.
Description
Technical Field
The invention relates to a cable, in particular to a composite cable integrating air pressure, electric power and signal transmission for a robot and a preparation method of the composite cable.
Background
The intelligent industrial equipment has the function of automatically executing the work task according to the set instruction, is the most typical electromechanical integrated digital equipment, such as a robot, is widely applied to replace human beings in automatic industrial production, and is described and illustrated in detail by taking the robot as an example.
The action of the robot needs to be ensured by means of electric power, control signals and pneumatic transmission, and corresponding wires and pipes are required to be arranged on the robot so as to ensure the effective and orderly transmission of the electric power, the signals and the gas.
Currently, pneumatic transmission tubes, power cables and signal cables arranged on mainstream robots are decentralized and independent, and in particular pneumatic transmission tubes cannot be integrated in the cables, which makes it necessary to install the pneumatic transmission system on the robot separately from the power and/or signal transmission system, resulting in a large space for arranging the pipelines in the robot. In order to reduce the line volume as much as possible in the line arrangement space arranged on the robot, it is common practice to dispose the separately installed pneumatic drive tubes with the power and/or signal transmission cables in a harness-integrated manner before the overall tube-passing arrangement. Therefore, although each pipeline arranged on the robot is relatively standard and orderly, the structure is still large in evacuation and volume, the requirement on the pipeline arrangement space is high, in other cases, the pneumatic transmission pipe is in linear connection, the pneumatic transmission pipe needs to be bent and moved regularly in the working process of the robot, and is easy to stretch and damage in the state, so that the service life of the robot is directly influenced, the maintenance of the robot is frequent, and the use cost is high.
In view of this, the cable design and manufacturing industry is developing various composite cables integrating pneumatic transmission, power transmission and signal transmission with each other for the special purpose of robots, and by using such composite cables, the pipelines arranged on robots can be made compact and long-lasting, and these research results are reported in the published chinese patent literature. However, although the disclosed research results have made the composite cable integrate pneumatic transmission, power transmission and signal transmission, and have been compact, the bending resistance and torsion resistance of the composite cable are insufficient due to the limitation of the cabling structure of the composite cable, and the composite cable is easily damaged, i.e. has a short service life, during repeated bending and torsion actions of the robot.
Disclosure of Invention
The technical purpose of the invention is that: aiming at the particularity of the intelligent industrial equipment and the defects of the existing composite cable, the composite cable for the robot, which has compact structure, tensile strength, bending resistance, torsion resistance and long service life, and the preparation method of the composite cable are provided.
The technical scheme adopted by the invention for achieving the technical purpose is that the composite cable for the robot is provided with a total cable core, an outer wrapping belt layer and an outer sheath layer, wherein the outer wrapping belt layer and the outer sheath layer are coated outside the total cable core; the total cable core is mainly formed by twisting at least one pneumatic transmission tube, at least one signal cable and at least one power cable, an outer filler is filled in a twisting gap of the total cable core, the signal cable and the power cable are respectively formed by twisting a plurality of insulating wire cores, and twisting directions of the insulating wire cores of the signal cable and the power cable are respectively the same as twisting directions of the total cable core. Further, the outer filler is polyester yarns, aramid yarns and/or cotton threads; the outer wrapping belt layer is of a non-woven fabric wrapping structure, and the wrapping overlapping rate is more than 25%; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material.
As one of the preferred schemes, the total cable core is formed by twisting two pneumatic transmission pipes, two signal cables with the same or different structures and three power cables with the same or different structures, in the twisting structure of the total cable core, the two pneumatic transmission pipes are symmetrically formed along the axial center of the total cable core, the two signal cables are symmetrically formed along the axial center of the total cable core, and the two power cables are symmetrically formed along the axial center of the total cable core.
As one of the preferred schemes, the signal cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are wrapped outside the cable core from inside to outside, wherein the cable core of the signal cable is mainly formed by twisting a plurality of twisted units, each twisted unit is provided with two insulating wire cores which are twisted together, a conductor of each insulating wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, the twisting direction of the insulating wire cores is the same as the twisting direction of the cable core of the signal cable, and the twisting gaps of the cable core of the signal cable are filled with fillers; and/or, the signal cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are wrapped outside the cable core from inside to outside, wherein the cable core of the signal cable is mainly formed by twisting a plurality of twisted units and at least one single insulating wire core, each twisted unit is provided with two insulating wire cores which are twisted together, a conductor of each insulating wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, the twisting direction of the insulating wire cores is the same as the twisting direction of the cable core of the signal cable, and a filler is filled in a twisting gap of the cable core of the signal cable. Further, the filler is polyester yarns, aramid yarns and/or cotton threads; the wrapping band layer is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tin-plated copper wires and aramid wires which are obliquely wrapped outside the cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of tensile non-woven fabrics, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material.
As one of the preferred schemes, the power cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are wrapped outside the cable core from inside to outside, wherein the cable core of the power cable is mainly formed by twisting a plurality of insulating wire cores, conductors of each insulating wire core are mainly formed by twisting a plurality of copper wires, the twisting direction of the insulating wire cores is the same as that of the cable core of the power cable, and filler is filled in a cable core twisting gap of the power cable. Further, the conductor of the insulated wire core is formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, and the twisting direction of the plurality of copper wires is the same as the twisting direction of each copper wire strand. The filler is polyester yarns, aramid yarns and/or cotton yarns; the wrapping band layer is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tin-plated copper wires and aramid wires which are obliquely wrapped outside the cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of tensile non-woven fabrics, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material.
The preparation method of the composite cable for the robot comprises the following steps:
Step 1, mixing a plurality of copper wires and aramid wires which are required to be in specification together, and twisting according to a pitch diameter ratio of 10-12 times to prepare a flexible tensile signal transmission conductor;
twisting a plurality of copper wires with required specifications into stranded wires according to a pitch diameter ratio of 10-12 times, and then twisting a plurality of stranded wires according to a design structure of the power transmission conductor according to the pitch diameter ratio of 10-12 times to prepare the power transmission conductor;
step 2, respectively extruding insulating layers on the signal transmission conductor and the power transmission conductor to respectively prepare a signal transmission insulating wire core and a power transmission insulating wire core;
Step 3, preparing a signal cable according to a cable core design structure of the signal transmission cable, which specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 6-8 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the plurality of twisted units in the step ① according to the pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and adding filler in the twisting process to prepare a cable core of the signal cable; and/or twisting the plurality of twisted pair units in the step ① and at least one signal transmission insulated wire core in the step 2 according to a pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and adding filler in the twisting process to prepare a cable core of the signal cable;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ② to obtain a signal cable;
Step 4, preparing a power cable according to a cable core design structure of the power transmission cable, wherein the method specifically comprises the following steps:
① Twisting the plurality of power transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 6-8 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and adding filler in the twisting process to prepare a cable core of the power cable;
② Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ① to obtain a power cable;
Step 5, twisting at least one signal cable prepared according to the step 3, at least one power cable prepared according to the step 4 and at least one prepared pneumatic transmission tube according to a pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the cable cores of the signal cable/the power cable, and filling materials are added in the twisting process to prepare a total cable core; when the number of the signal cables is plural, the structures of the signal cables are the same or different, and when the number of the power cables is plural, the structures of the power cables are the same or different;
And forming an outer wrapping layer and an outer sheath layer outside the total cable core in sequence to prepare the composite cable integrating pneumatic transmission, power transmission and signal transmission. Further, the filler is polyester yarns, aramid yarns and/or cotton threads; the wrapping band layer is an aluminum-plastic composite band wrapped outside the corresponding cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the corresponding cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of a tensile non-woven fabric, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material; the outer wrapping belt layer is of a non-woven fabric wrapping structure, and the wrapping overlapping rate is more than 25%; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material.
The beneficial technical effects of the invention are as follows:
1. The composite cable of the invention effectively, stably and compactly integrates the functions of pneumatic transmission, power transmission and signal transmission, the cable structure can ensure that the product has excellent flexibility and tensile strength and good bending and torsion resistance (the bending resistance and torsion resistance of the composite cable can respectively reach more than 1000 ten thousand times through experiments), the service life of the composite cable is long, and the composite cable is particularly suitable for robots with repeated bending and torsion actions;
2. In the total cable core stranding structure of the composite cable, the two air pressure transmission pipes are symmetrically stranded and formed along the axial center of the total cable core, the two signal cables are symmetrically formed along the axial center of the total cable core, so that the structure of the total cable core can be compact, and the air pressure, signals and electric power can be transmitted stably, particularly, the air pressure transmission pipes are most obvious, the air pressure transmission pipes which are symmetrically stranded can ensure that the air pressure transmission stress is balanced and the compression is smaller in the use process, the damage of the air pressure transmission pipes caused by unbalanced compression is effectively avoided, and the whole service life of the composite cable is further effectively prolonged;
3. The preparation method of the invention is provided for the composite cable, and has strong pertinence; in the preparation method, the corresponding conductors are stranded according to a specific pitch diameter ratio, the conductors, the cable cores and the total cable core are stranded according to a uniform direction, and meanwhile reinforcing materials are attached to the corresponding conductors and the cable cores, so that the prepared composite cable effectively integrates the functions of pneumatic transmission, power transmission and signal transmission, and the composite cable has a compact structure, is good in stability in the use process, has excellent flexibility and structural strength, and is excellent in bending resistance and torsion resistance (the bending resistance and the torsion resistance of the composite cable can reach more than 1000 ten thousand times respectively through experiments), and has good tensile property and long service life.
Drawings
Fig. 1 is a schematic view of a structure of the present invention.
Fig. 2 is a schematic structural view of the first signal cable in fig. 1.
Fig. 3 is a schematic structural diagram of the second signal cable in fig. 1.
Fig. 4 is a schematic structural view of the first power cable in fig. 1.
Fig. 5 is a schematic structural diagram of the second power cable in fig. 1.
The meaning of the symbols in the figures: 1-an air pressure transmission tube; 2-a first signal cable; 21-a twisted pair unit; 22-conductors; 23-an insulating layer; 24-filler; 25-belting layer; 26-a shielding layer; 27-a sheath layer; 3-a second signal cable; 31-a twisted pair unit; 32-conductors; 33-an insulating layer; 34—a filler; 35-a belting layer; 36-a shielding layer; 37-a sheath layer; 38-single insulated wire core; 4-a first power cable; 41-conductors; 42-an insulating layer; 43-filler; 44-a tape layer; 45-a shielding layer; 46-a sheath layer; 5-a second power cable; 51-conductor; 52-an insulating layer; 53-filler; 54-a tape layer; 55-a shielding layer; 56-a sheath layer; 6-an outer filler; 7-an outer belt layer; 8-an outer sheath layer.
Detailed Description
The invention relates to a composite cable integrating three functions of pneumatic transmission, electric power transmission and signal transmission and a preparation method of the composite cable. The composite cable is particularly suitable for robots and can be applied to other intelligent industrial equipment. The technical content of the present invention will be described in detail with reference to the following embodiments, wherein embodiment 1 is described in detail with reference to the accompanying drawings, i.e. fig. 1 to 5, and other embodiments are not separately drawn, but the main technical points can still refer to the accompanying drawings of embodiment 1.
Example 1
Referring to fig. 1, the invention comprises a total cable core, an outer wrapping layer 7 and an outer sheath layer 8, wherein the outer wrapping layer 7 and the outer sheath layer are wrapped outside the total cable core; the outer wrapping layer 7 is a non-woven fabric wrapping structure, and the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., and is specific to the design requirement; the outer sheath layer 8 is an extrusion structure of TPE material, which is coated on the outer sheath layer 7 of the total cable core, and of course, the outer sheath layer 8 can also be formed by extrusion of TPU material or PVC material, and the choice of specific materials is also determined according to design requirements. The total cable core is formed by twisting two pneumatic transmission pipes 1, two signal cables (namely a first signal cable 2 and a second signal cable 3) and three power cables (namely a first power cable 4 and a second power cable 5, wherein the first power cable 4 is two), in the twisting structure of the total cable core, the second power cable 5 is centered, the two pneumatic transmission pipes 1 are symmetrically formed along the axial center of the total cable core, the two signal cables (namely the first signal cable 2 and the second signal cable 3) are symmetrically formed along the axial center of the total cable core, and the two power cables (namely the first power cable 4) are symmetrically formed along the axial center of the total cable core. The twisting gaps of the total cable core are filled with an outer filler 6 of a wire harness structure, and the outer filler 6 is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the outer filler is determined according to design requirements. The signal cable and the power cable are formed by twisting a plurality of insulated conductors, and the twisting directions of the insulated conductors of the signal cable and the power cable are the same as the twisting directions of the total cable core.
The first signal cable 2, the second signal cable 4 and the second power cable 5 in the total cable core are specifically described below.
Referring to fig. 2, the first signal cable 2 mainly comprises a cable core, a wrapping tape layer 25, a shielding layer 26 and a sheath layer 27, wherein the wrapping tape layer 25 is wrapped outside the cable core from inside to outside. The wrapping layer 25 is an aluminum-plastic composite belt wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite belt is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to design requirements. The shielding layer 26 is a mixture of tin-plated copper wires and aramid wires obliquely wrapped on the outer part of the cable core wrapping layer 25, and the oblique wrapping density of the shielding layer 26 is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, etc., according to design requirements. The sheath layer 27 is a wrapping structure of a tensile non-woven fabric wrapped outside the shielding layer 26, and the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to the design requirement; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the first signal cable 2 is mainly formed by twisting four twisted units 21, wherein the twisting gaps of the twisted units are filled with fillers 24 with a wire harness structure, the outer fillers 24 are a mixture of polyester yarns, aramid yarns and cotton threads, can be a mixture of the polyester yarns, the aramid yarns and the cotton threads, and can be one material of the polyester yarns, the aramid yarns and the cotton threads according to the design requirement; each pair twisting unit 21 is provided with two twisted insulated wire cores, each insulated wire core mainly comprises a conductor 22 and an insulating layer 23 coated outside the conductor 22, the conductor 22 of each insulated wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, and the twisting direction of each insulated wire core is the same as the twisting direction of the cable core of the first signal cable 2.
Referring to fig. 3, the second signal cable 3 mainly comprises a cable core, a wrapping tape layer 35, a shielding layer 36 and a sheath layer 37, wherein the wrapping tape layer 35, the shielding layer 36 and the sheath layer 37 are coated outside the cable core from inside to outside. The wrapping band layer 35 is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., and is specific depending on design requirements. The shielding layer 36 is a mixture of tin-plated copper wires and aramid wires obliquely wrapped on the outer part of the cable core wrapping layer 35, and the oblique wrapping density of the shielding layer 36 is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, etc., according to design requirements. The sheath layer 37 is a wrapping structure of a tensile non-woven fabric wrapped outside the shielding layer 36, and the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to the design requirement; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the second signal cable 3 is mainly formed by twisting four twisted units 31 and a single insulating wire core 38, wherein a filler 34 with a wire harness structure is filled in a twisting gap of the twisted units, the outer filler 34 is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the two of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; each twisted pair unit 31 has two insulated wire cores twisted together, each insulated wire core mainly comprises a conductor 32 and an insulating layer 33 coated outside the conductor, the conductor of each insulated wire core (comprising the insulated wire core of the twisted pair unit 31 and the insulated wire core of the single insulated wire core 38) is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, and the twisting direction of the insulated wire cores (comprising the insulated wire core of the twisted pair unit 31 and the insulated wire core of the single insulated wire core 38) is the same as the twisting direction of the cable core of the second signal cable 3.
Referring to fig. 4, the first power cable 4 mainly comprises a cable core, a wrapping tape layer 44, a shielding layer 45 and a sheath layer 46, wherein the wrapping tape layer 44 is coated outside the cable core from inside to outside. The wrapping band layer 44 is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to design requirements. The shielding layer 45 is a mixture of tin-plated copper wires and aramid wires obliquely wrapped on the outer part of the cable core wrapping layer 44, and the oblique wrapping density of the shielding layer 45 is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, etc., according to design requirements. The sheath layer 46 is a wrapping structure of a tensile non-woven fabric wrapped outside the shielding layer 45, and the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to the design requirement; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the first power cable 4 is mainly formed by twisting four insulating cable cores, a filler 43 with a wire harness structure is filled in twisting gaps of the four insulating cable cores, the outer filler 43 is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the two polyester yarns, the aramid yarns and the cotton yarns, and can also be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the outer filler 43 is determined according to design requirements; each insulated wire core mainly comprises a conductor 41 and an insulating layer 42 coated outside the conductor 41, the conductor 41 of each insulated wire core is mainly formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, the twisting direction of the copper wire strands is the same as that of each copper wire strand, and the twisting direction of each copper wire strand is the same as that of the cable core of the power cable 4.
Referring to fig. 5, the second power cable 5 mainly comprises a cable core, a wrapping tape layer 54, a shielding layer 55 and a sheath layer 56, wherein the wrapping tape layer 54, the shielding layer 55 and the sheath layer 56 are coated outside the cable core from inside to outside. The wrapping band layer 54 is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to design requirements. The shielding layer 55 is a mixture of tin-plated copper wires and aramid wires obliquely wrapped around the cable core wrapping layer 54, and the oblique wrapping density of the shielding layer 55 is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, etc., depending on design requirements. The sheath layer 56 is a wrapping structure of a tensile non-woven fabric wrapped outside the shielding layer 55, and the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, etc., which is determined according to the design requirement; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the power cable II 5 is mainly formed by twisting six insulating cable cores, a filler 53 with a wire harness structure is filled in twisting gaps of the six insulating cable cores, the outer filler 53 is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the two polyester yarns, the aramid yarns and the cotton yarns, and can also be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the outer filler 53 is determined according to the design requirement; each insulated wire core mainly comprises a conductor 51 and an insulating layer 52 coated outside the conductor 51, the conductor 51 of each insulated wire core is mainly formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, the twisting direction of the copper wire strands is the same as that of each copper wire strand, and the twisting direction of each copper wire strand is the same as that of the cable core of the power cable II 5.
The preparation method of the composite cable comprises the following steps:
Step 1, pulling a copper rod to a monofilament with a required specification through copper middle pulling equipment, copper small pulling equipment and the like;
mixing a plurality of copper wires and aramid wires with required specifications together, twisting according to a pitch diameter ratio of 11 times, setting the twisting direction to be left, and keeping the tension of each coil consistent during paying off to prepare a flexible tensile signal transmission conductor;
twisting a plurality of copper wires with required specifications into a strand according to a pitch diameter ratio of 11 times, wherein the twisting direction is set to be left; then, twisting multiple strands according to the design structure (for example, a 1+6 normal structure or a 1+6+12 normal structure) of the power transmission conductor according to the pitch diameter ratio of 11 times, wherein the twisting direction is set to be left, and a cage twisting machine with a back twisting device or a spiral arm single twisting machine with an active paying-off function is adopted for twisting; preparing a power transmission conductor;
step 2, respectively extruding insulating layers on the signal transmission conductor and the power transmission conductor to respectively prepare a signal transmission insulating wire core and a power transmission insulating wire core;
step 3, preparing a first signal cable according to a cable core design structure of the first signal transmission cable, wherein the method specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 7 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and the twisting is realized by processing twisted pair equipment with a untwisting device, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the four twisted units in the step ① according to a pitch diameter ratio of 9 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable core of the first manufactured signal cable, wherein the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the first signal cable is prepared according to the design requirement;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ②; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; obtaining a first signal cable;
step 4, preparing a second signal cable according to a cable core design structure of the second signal transmission cable, wherein the method specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 7 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and the twisting is realized by processing twisted pair equipment with a untwisting device, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the four twisted pair units in the step ① and the insulated wire core of one signal transmission in the step 2 according to a pitch diameter ratio of 9 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and roundness of the cable core of the manufactured signal cable II, and the twisting is realized by adopting cabling equipment with a untwisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the second signal cable is prepared according to the design requirement;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ②; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; obtaining a second signal cable;
step 5, preparing a first power cable according to a cable core design structure of the first power transmission cable, wherein the first power cable specifically comprises the following steps:
① Twisting the four power transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 7 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable core of the first manufactured power cable, wherein the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the first power cable is prepared according to the design requirement;
② Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ①; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; manufacturing a first power cable;
Step 6, preparing a second power cable according to a cable core design structure of the second power transmission cable, wherein the second power cable specifically comprises the following steps:
① Twisting the six power transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 7 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable core of the manufactured power cable II, and the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the outer filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the power cable II is prepared according to the design requirement;
② Forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ① in sequence, wherein the wrapping layer is an aluminum-plastic composite belt, the wrapping layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; obtaining a second power cable;
Step 7, combining a first signal cable manufactured according to the step 3, a second signal cable manufactured according to the step 4, two first power cables manufactured according to the step 5, a second power cable manufactured according to the step 6 and two prepared pneumatic transmission pipes together, wherein the combined structure centers the second power cable, the two pneumatic transmission pipes are symmetrically arranged on the periphery of the second power cable, the first signal cable and the second signal cable are symmetrically arranged on the periphery of the second power cable, and the first power cables are symmetrically arranged on the periphery of the second power cable; twisting two pneumatic transmission pipes, two signal cables and three power cables which are combined together according to the pitch diameter ratio of 9 times, wherein the twisting direction is the same as the twisting direction of cable cores of the signal cables/the power cables, fillers with a wire harness structure are added in the twisting process, so that the tensile property and the roundness of the total cable core are ensured, and the twisting is realized by adopting cabling equipment with an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; preparing a total cable core;
Forming an outer wrapping band layer and an outer sheath layer outside the total cable core in sequence; the outer wrapping layer is a non-woven fabric wrapping structure, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the outer wrapping layer is specific to design requirements; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material, and the selection of specific materials is determined according to design requirements; thus, a composite cable integrating pneumatic transmission, power transmission and signal transmission is manufactured.
Example 2
The invention has a total cable core, an outer wrapping layer and an outer sheath layer, wherein the outer wrapping layer is wrapped outside the total cable core; the outer wrapping layer is a non-woven fabric wrapping structure, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the outer wrapping layer is specific to the design requirement; the outer sheath layer is an extrusion structure of TPE material, and is coated on the outer sheath layer of the total cable core, of course, the outer sheath layer can also be formed by extrusion of TPU material or PVC material, and the selection of specific materials is also determined according to design requirements. The total cable core is formed by twisting an air pressure transmission pipe, a signal cable and three power cables with the same structure, and the twisting gaps of the total cable core are filled with outer fillers with a wire harness structure, wherein the outer fillers are a mixture of polyester yarns, aramid yarns and cotton yarns, can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, and can be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement. The signal cable and the power cable are formed by twisting a plurality of insulating wire cores, and the twisting directions of the insulating wire cores of the signal cable and the power cable are the same as the twisting directions of the total cable cores.
The signal cable and the power cable in the total cable core are now described in detail as follows.
The signal cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are coated outside the cable core from inside to outside. The wrapping layer is an aluminum-plastic composite belt wrapped outside the cable core, the wrapping overlapping rate of the aluminum-plastic composite belt is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to design requirements. The shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the cable core wrapping layer, and the oblique wrapping density of the shielding layer is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, and the like, and is determined according to design requirements. The sheath layer is a wrapping structure of the tensile non-woven fabrics wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is specific to design requirements; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the signal cable is mainly formed by twisting four twisted units, wherein the twisting gaps are filled with fillers with a wire harness structure, the outer fillers are a mixture of polyester yarns, aramid yarns and cotton threads, and can be a mixture of the polyester yarns, the aramid yarns and the cotton threads or a material of the polyester yarns, the aramid yarns and the cotton threads according to the design requirement; each pair twisting unit is provided with two twisted insulated wire cores, each insulated wire core mainly comprises a conductor and an insulating layer coated outside the conductor, the conductor of each insulated wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, and the twisting direction of the insulated wire cores is the same as the twisting direction of the cable cores of the signal cable.
The power cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are coated outside the cable core from inside to outside. The wrapping layer is an aluminum-plastic composite belt wrapped outside the cable core, the wrapping overlapping rate of the aluminum-plastic composite belt is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to design requirements. The shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the cable core wrapping layer, and the oblique wrapping density of the shielding layer is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, and the like, and is determined according to design requirements. The sheath layer is a wrapping structure of the tensile non-woven fabrics wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is specific to design requirements; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the power cable is mainly formed by twisting four insulating wire cores, wherein the twisting gaps of the cable core are filled with fillers with a wire harness structure, the outer fillers are a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, and can also be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; each insulated wire core mainly comprises a conductor and an insulating layer coated outside the conductor, the conductor of each insulated wire core is mainly formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, the twisting direction of the plurality of copper wires is the same as the twisting direction of each copper wire strand, and the twisting direction of each copper wire strand is the same as the twisting direction of the cable core of the power cable.
The preparation method of the composite cable comprises the following steps:
Step 1, pulling a copper rod to a monofilament with a required specification through copper middle pulling equipment, copper small pulling equipment and the like;
mixing a plurality of copper wires and aramid wires with required specifications together, twisting according to a 12-time pitch diameter ratio, setting the twisting direction to be left, and keeping the tension of each coil consistent during paying off to prepare a flexible tensile signal transmission conductor;
twisting a plurality of copper wires with required specifications into a strand according to a pitch diameter ratio of 12 times, wherein the twisting direction is set to be left; then, twisting multiple strands according to a 12-time pitch diameter ratio according to a design structure (for example, a 1+6 normal structure or a 1+6+12 normal structure) of the power transmission conductor, wherein the twisting direction is set to be left, and a cage twisting machine with a back twisting device or a spiral arm single twisting machine with an active paying-off function is adopted for twisting; preparing a power transmission conductor;
step 2, respectively extruding insulating layers on the signal transmission conductor and the power transmission conductor to respectively prepare a signal transmission insulating wire core and a power transmission insulating wire core;
Step 3, preparing a signal cable according to a cable core design structure of the signal transmission cable, which specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 8 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and the twisting is realized by processing twisted pair equipment with a untwisting device, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the four twisted units in the step ① according to a pitch diameter ratio of 10 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable core of the manufactured signal cable, wherein the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the signal cable is prepared according to the design requirement;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ②; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; a signal cable is manufactured;
Step 4, preparing a power cable according to a cable core design structure of the power transmission cable, wherein the method specifically comprises the following steps:
① Twisting the four power transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 8 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable cores of the prepared signal cables, and the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the power cable is prepared according to the design requirement;
② Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ①; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; the power cable is manufactured;
Step 5, combining one signal cable prepared according to the step 3, three power cables prepared according to the step 4 and one prepared pneumatic transmission tube; twisting a pneumatic transmission tube, a signal cable and three power cables which are combined together according to the pitch diameter ratio of 10 times, wherein the twisting direction is the same as the twisting direction of cable cores of the signal cable/the power cables, fillers with a wire harness structure are added in the twisting process, so that the tensile property and the rounding property of the total cable core are ensured, and the twisting is realized by adopting cabling equipment with an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; preparing a total cable core;
Forming an outer wrapping band layer and an outer sheath layer outside the total cable core in sequence; the outer wrapping layer is a non-woven fabric wrapping structure, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the outer wrapping layer is specific to design requirements; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material, and the selection of specific materials is determined according to design requirements; thus, a composite cable integrating pneumatic transmission, power transmission and signal transmission is manufactured.
Example 3
The invention has a total cable core, an outer wrapping layer and an outer sheath layer, wherein the outer wrapping layer is wrapped outside the total cable core; the outer wrapping layer is a non-woven fabric wrapping structure, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the outer wrapping layer is specific to the design requirement; the outer sheath layer is an extrusion structure of TPE material, and is coated on the outer sheath layer of the total cable core, of course, the outer sheath layer can also be formed by extrusion of TPU material or PVC material, and the selection of specific materials is also determined according to design requirements. The total cable core is formed by twisting two pneumatic transmission pipes, two signal cables with the same structure and three power cables with the same structure, in the twisting structure of the total cable core, one power cable is centered, the two pneumatic transmission pipes are symmetrically formed along the axial center of the total cable core, the two signal cables are symmetrically formed along the axial center of the total cable core, and the remaining two power cables are symmetrically formed along the axial center of the total cable core. The twisted gaps of the total cable core are filled with an outer filler of a wire harness structure, the outer filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and of course, the outer filler can also be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, and can also be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the outer filler is determined according to design requirements. The signal cable and the power cable are formed by twisting a plurality of insulating wire cores, and the twisting directions of the insulating wire cores of the signal cable and the power cable are the same as the twisting directions of the total cable cores.
The signal cable and the power cable in the total cable core are now described in detail as follows.
The signal cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are coated outside the cable core from inside to outside. The wrapping layer is an aluminum-plastic composite belt wrapped outside the cable core, the wrapping overlapping rate of the aluminum-plastic composite belt is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to design requirements. The shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the cable core wrapping layer, and the oblique wrapping density of the shielding layer is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, and the like, and is determined according to design requirements. The sheath layer is a wrapping structure of the tensile non-woven fabrics wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is specific to design requirements; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the signal cable is mainly formed by twisting four twisted units and a single insulating wire core, wherein the twisting gaps of the twisted units are filled with fillers with a wire harness structure, the outer fillers are a mixture of polyester yarns, aramid yarns and cotton wires, can be a mixture of the polyester yarns, the aramid yarns and the cotton wires, and can be one material of the polyester yarns, the aramid yarns and the cotton wires according to the design requirement; each pair twisting unit is provided with two twisted insulated wire cores, each insulated wire core mainly comprises a conductor and an insulating layer coated outside the conductor, each conductor of each insulated wire core (comprising the insulated wire core of the pair twisting unit and the insulated wire core of the single insulated wire core) is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, and the twisting direction of each insulated wire core (comprising the insulated wire core of the pair twisting unit and the insulated wire core of the single insulated wire core) is the same as the twisting direction of the cable core of the signal cable.
The power cable mainly comprises a cable core, and a wrapping layer, a shielding layer and a sheath layer which are coated outside the cable core from inside to outside. The wrapping layer is an aluminum-plastic composite belt wrapped outside the cable core, the wrapping overlapping rate of the aluminum-plastic composite belt is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to design requirements. The shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the cable core wrapping layer, and the oblique wrapping density of the shielding layer is more than 90%, for example, the oblique wrapping density is 90%, 94% or 98%, and the like, and is determined according to design requirements. The sheath layer is a wrapping structure of the tensile non-woven fabrics wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is specific to design requirements; of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, which is determined according to design requirements. The cable core of the power cable is mainly formed by twisting six insulated conductors, wherein the twisting gaps of the cable core are filled with fillers with a wire harness structure, the outer fillers are a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, and can also be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; each insulated wire core mainly comprises a conductor and an insulating layer coated outside the conductor, the conductor of each insulated wire core is mainly formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, the twisting direction of the plurality of copper wires is the same as the twisting direction of each copper wire strand, and the twisting direction of each copper wire strand is the same as the twisting direction of the cable core of the power cable.
The preparation method of the composite cable comprises the following steps:
Step 1, pulling a copper rod to a monofilament with a required specification through copper middle pulling equipment, copper small pulling equipment and the like;
Mixing a plurality of copper wires and aramid wires with required specifications together, twisting according to a pitch diameter ratio of 10 times, setting the twisting direction to be left, and keeping the tension of each coil consistent during paying off to prepare a flexible tensile signal transmission conductor;
Twisting a plurality of copper wires with required specifications into a strand according to a pitch diameter ratio of 10 times, wherein the twisting direction is set to be left; then, twisting multiple strands according to a 10-time pitch diameter ratio according to a design structure (for example, a 1+6 normal structure or a 1+6+12 normal structure) of the power transmission conductor, wherein the twisting direction is set to be left, and a cage twisting machine with a back twisting device or a spiral arm single twisting machine with an active paying-off function is adopted for twisting; preparing a power transmission conductor;
step 2, respectively extruding insulating layers on the signal transmission conductor and the power transmission conductor to respectively prepare a signal transmission insulating wire core and a power transmission insulating wire core;
Step 3, preparing a signal cable according to a cable core design structure of the signal transmission cable, which specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 6 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and the twisting is realized by processing twisted pair equipment with a untwisting device, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the four twisted pair units in the step ① and the insulated wire core for signal transmission in the step 2 according to the pitch diameter ratio of 8 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable core of the manufactured signal cable, and the twisting is realized by adopting cabling equipment with a untwisting device or an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the signal cable is prepared according to the design requirement;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ②; the wrapping tape layer is an aluminum-plastic composite tape, the wrapping tape layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; a signal cable is manufactured;
Step 4, preparing a power cable according to a cable core design structure of the power transmission cable, wherein the method specifically comprises the following steps:
① Twisting the six power transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 6 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and filling materials with a wire harness structure are added in the twisting process to ensure the tensile property and the rounding property of the cable cores of the manufactured power cables, and the twisting is realized by adopting cable forming equipment with a back twisting device or an active paying-off function; the outer filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns, and the cable core of the power cable is prepared according to the design requirement;
② Forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ① in sequence, wherein the wrapping layer is an aluminum-plastic composite belt, the wrapping layer is wrapped outside the cable core, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the wrapping overlapping rate is determined according to the design requirement; the shielding layer is a mixture of tinned copper wires and aramid fibers, the inclined package density of the shielding layer is more than 90%, for example, the inclined package density is 90%, 94% or 98%, and the like, and the shielding layer is specific to design requirements; the sheath layer is made of tensile non-woven fabrics, the sheath layer is wrapped outside the shielding layer, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the sheath layer is determined according to the design requirement, and of course, the sheath layer can also be an extrusion structure made of TPE material, TPU material or PVC material, and the sheath layer is determined according to the design requirement; the power cable is manufactured;
Step 5, combining the two signal cables manufactured according to the step 3, the three power cables manufactured according to the step 4 and the two prepared pneumatic transmission pipes together, wherein the combined structure centers one power cable, the two pneumatic transmission pipes are symmetrically arranged on the periphery of the centered power cable, the two signal cables are symmetrically arranged on the periphery of the centered power cable, and the remaining two power cables are symmetrically arranged on the periphery of the centered power cable; twisting two pneumatic transmission pipes, two signal cables and three power cables which are combined together according to the pitch diameter ratio of 8 times, wherein the twisting direction is the same as the twisting direction of cable cores of the signal cables/the power cables, fillers with a wire harness structure are added in the twisting process, so that the tensile property and the roundness of the total cable core are ensured, and the twisting is realized by adopting cabling equipment with an active paying-off function; the filler is a mixture of polyester yarns, aramid yarns and cotton yarns, and can be a mixture of the polyester yarns, the aramid yarns and the cotton yarns, or can be one material of the polyester yarns, the aramid yarns and the cotton yarns according to the design requirement; preparing a total cable core;
Forming an outer wrapping band layer and an outer sheath layer outside the total cable core in sequence; the outer wrapping layer is a non-woven fabric wrapping structure, the wrapping overlapping rate is more than 25%, for example, the wrapping overlapping rate is 25%, 30% or 35%, and the like, and the outer wrapping layer is specific to design requirements; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material, and the selection of specific materials is determined according to design requirements; thus, a composite cable integrating pneumatic transmission, power transmission and signal transmission is manufactured.
The above examples are only for illustrating the invention and are not to be construed as limiting the invention; although the invention has been described in detail with reference to the above embodiments, it will be understood by those of ordinary skill in the art that: the invention may be modified or substituted for some of the features of the embodiments described above without departing from the spirit and scope of the invention.
Claims (3)
1. The utility model provides a composite cable for robot which characterized in that:
the composite cable is provided with a total cable core, an outer wrapping layer (7) and an outer sheath layer (8), wherein the outer wrapping layer is wrapped outside the total cable core;
The total cable core is formed by twisting two pneumatic transmission pipes (1), two signal cables with the same or different structures and three power cables with the same or different structures, wherein in the twisting structure of the total cable core, the two pneumatic transmission pipes (1) are symmetrically formed along the axial center of the total cable core, the two signal cables are symmetrically formed along the axial center of the total cable core, and the two power cables are symmetrically formed along the axial center of the total cable core;
An outer filler (6) is filled in the twisting gaps of the total cable core, and the outer filler (6) is polyester yarns, aramid yarns and/or cotton yarns;
the signal cable and the power cable are formed by twisting a plurality of insulating wire cores respectively, and the twisting directions of the insulating wire cores of the signal cable and the power cable are the same as the twisting directions of the total cable cores respectively;
The outer wrapping belt layer (7) is of a non-woven fabric wrapping structure, and the wrapping overlapping rate is more than 25%;
The outer sheath layer (8) is an extrusion structure of TPE material, TPU material or PVC material;
The signal cable mainly comprises a cable core, a wrapping layer, a shielding layer and a sheath layer, wherein the wrapping layer, the shielding layer and the sheath layer are wrapped outside the cable core from inside to outside, the cable core of the signal cable is mainly formed by twisting a plurality of twisted units, each twisted unit is provided with two insulating wire cores which are twisted together, a conductor of each insulating wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, the twisting direction of the insulating wire cores is the same as that of the cable core of the signal cable, and filling materials are filled in twisting gaps of the cable core of the signal cable; and/or the signal cable mainly comprises a cable core, a wrapping layer, a shielding layer and a sheath layer, wherein the wrapping layer, the shielding layer and the sheath layer are wrapped outside the cable core from inside to outside, the cable core of the signal cable is mainly formed by twisting a plurality of twisted units and at least one single insulating wire core, each twisted unit is provided with two insulating wire cores which are twisted together, a conductor of each insulating wire core is mainly formed by twisting a plurality of copper wires and a plurality of aramid wires, the twisting direction of each insulating wire core is the same as the twisting direction of the cable core of the signal cable, and a filler is filled in a twisting gap of the cable core of the signal cable; the filler is polyester yarns, aramid yarns and/or cotton yarns; the wrapping band layer is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tin-plated copper wires and aramid wires which are obliquely wrapped outside the cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of a tensile non-woven fabric, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material;
The cable core of the power cable is mainly formed by twisting a plurality of insulating wire cores, conductors of each insulating wire core are mainly formed by twisting a plurality of copper wires, the twisting direction of the insulating wire cores is the same as that of the cable core of the power cable, and filler is filled in a twisting gap of the cable core of the power cable; the conductor of the insulated wire core is formed by twisting a plurality of copper wire strands, each copper wire strand is formed by twisting a plurality of copper wires, and the twisting direction of the plurality of copper wires is the same as the twisting direction of each copper wire strand; the filler is polyester yarns, aramid yarns and/or cotton yarns; the wrapping band layer is an aluminum-plastic composite band wrapped outside the cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tin-plated copper wires and aramid wires which are obliquely wrapped outside the cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of tensile non-woven fabrics, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material.
2. A method of manufacturing the composite cable for a robot according to claim 1, comprising the steps of:
Step 1, mixing a plurality of copper wires and aramid wires which are required to be in specification together, and twisting according to a pitch diameter ratio of 10-12 times to prepare a flexible tensile signal transmission conductor;
twisting a plurality of copper wires with required specifications into stranded wires according to a pitch diameter ratio of 10-12 times, and then twisting a plurality of stranded wires according to a design structure of the power transmission conductor according to the pitch diameter ratio of 10-12 times to prepare the power transmission conductor;
step 2, respectively extruding insulating layers on the signal transmission conductor and the power transmission conductor to respectively prepare a signal transmission insulating wire core and a power transmission insulating wire core;
Step 3, preparing a signal cable according to a cable core design structure of the signal transmission cable, which specifically comprises the following steps:
① Twisting the two signal transmission insulating wire cores in the step 2 according to a pitch diameter ratio of 6-8 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, so as to obtain a twisted pair unit; repeating the steps to obtain a plurality of twisted pair units;
② Twisting the plurality of twisted units in the step ① according to the pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and adding filler in the twisting process to prepare a cable core of the signal cable; and/or twisting the plurality of twisted pair units in the step ① and at least one signal transmission insulated wire core in the step 2 according to a pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the signal transmission conductor, and adding filler in the twisting process to prepare a cable core of the signal cable;
③ Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ② to obtain a signal cable;
Step 4, preparing a power cable according to a cable core design structure of the power transmission cable, wherein the method specifically comprises the following steps:
① Twisting the plurality of power transmission insulating wire cores in the step 2 according to the pitch diameter ratio of 6-8 times, wherein the twisting direction is the same as the twisting direction of the power transmission conductors, and adding filler in the twisting process to prepare a cable core of the power cable;
② Sequentially forming a wrapping layer, a shielding layer and a sheath layer outside the cable core in the step ① to obtain a power cable;
Step 5, twisting at least one signal cable prepared according to the step 3, at least one power cable prepared according to the step 4 and at least one prepared pneumatic transmission tube according to a pitch diameter ratio of 8-10 times, wherein the twisting direction is the same as the twisting direction of the cable cores of the signal cable/the power cable, and filling materials are added in the twisting process to prepare a total cable core; when the number of the signal cables is plural, the structures of the signal cables are the same or different, and when the number of the power cables is plural, the structures of the power cables are the same or different;
And forming an outer wrapping layer and an outer sheath layer outside the total cable core in sequence to prepare the composite cable integrating pneumatic transmission, power transmission and signal transmission.
3. The method for manufacturing a composite cable for a robot according to claim 2, wherein: the filler is polyester yarns, aramid yarns and/or cotton yarns; the wrapping band layer is an aluminum-plastic composite band wrapped outside the corresponding cable core, and the wrapping overlapping rate of the aluminum-plastic composite band is more than 25%; the shielding layer is a mixture of tinned copper wires and aramid wires obliquely wrapped outside the corresponding cable core, and the oblique wrapping density of the shielding layer is more than 90%; the sheath layer is of a wrapping structure of a tensile non-woven fabric, the wrapping overlapping rate is more than 25%, or the sheath layer is of an extrusion structure of TPE material, TPU material or PVC material; the outer wrapping belt layer is of a non-woven fabric wrapping structure, and the wrapping overlapping rate is more than 25%; the outer sheath layer is an extrusion structure of TPE material, TPU material or PVC material.
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